Spring suspension mat

ABSTRACT

In a spring suspension mat ( 10 ), more especially for the cushioning of seats, beds or chairs of all types, said mat having spring members ( 12 ), which are disposed adjacent each other in a first direction substantially parallel to a surface, which is usable by a user, with spring parts ( 12   a ), which stand up transversely relative to the useable surface, the spring members being interconnected for operative connection via connecting means ( 14 ) transversely relative to their first direction substantially parallel to the surface, wherein the spring parts ( 12   a ) with the spring members are one-piece sections of the spring members ( 12 ) and are generally formed from the same and in that the spring parts are nevertheless, where necessary, resiliently deformable individually, independently of each other, the desired impression of sitting on something soft is created saving space in an alternative manner (FIG.  1, 2 ).

REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation in part of PCT applicationPCT/EP 02/12299, filed on Nov. 4, 2002, the entire contents of which areincorporated by reference herein. This application is also related toand claims the priority of German Utility Model 202 07 605.9, filed onMay 15, 2002, the entire contents of which are incorporated by referenceherein, and European Patent Application No. 03 010 551.4, the entirecontents of which are incorporated by reference herein.

FIELD OF THE INVENTION

[0002] The invention relates to a spring suspension mat, more especiallyfor the cushioning of seats and the like in accordance with the mainpreamble of claim 1.

PRIOR ART

[0003] FR 906 564 A makes known a spring base for seating which is atype of spring suspension mat in accordance with the main preamble ofclaim 1. Individual spring members are formed from spring-steel crossbands, one-piece spring parts being disposed with the spring members insuch a manner that their height under load is reduced withoutinfluencing the remaining spring members. The spring members can bepacked in plastics foam in the upholstery. On account of the bendingradii of the spring members, the overall height nevertheless remainsconsiderable, as the spring members continuously require a minimumheight, if plastic deforming of the spring members is to be avoided infavor of the durability of the spring action. The spring membersthemselves are suspended in a support frame parallel to each other.

[0004] DE 317 362 C makes known a spring base for seating according tothe main preamble of claim 1. Individual spring members are formed fromspring-steel cross bands and are then suspended parallel to each otherin a pre-tensioned manner in a wire frame. The pre-tensioning as well asthe separation between spring member and support member increases notonly the overall height of the spring base. As the individual springsare not suspended together, not even in a row, displacements areproduced which allow individual springs to be felt when sat upon. Thiseffect is increased even more through the pre-tensioning of the springmembers required in this case. Individual shaping of spring members isalso known in DE 100 23 466 A1.

[0005] DE 24 00 992 A1 and DE 24 00 993 A1 show an upholstery made ofinextensible material which receives its resilience via spring bridgeportions. This consequently produces a deflection property in thesurface, as because the individual members are not extensible, thedesired point deflection is not produced. The narrowly spaceddisposition restricts the deformability of the upholstery.

[0006] DE 650 903 C makes known a tension-loaded spring base with flatspring members.

[0007] The tension-loaded spring members produce an uncomfortable, hardimpression as they prevent the load being accommodated point-by-point ina resilient manner. In addition, there is no flat structure, which meansthat an additional framework is necessary.

[0008] Spring suspension members are also sometimes formed by theupholstery of seats, beds or the like, and have the job of making theuser feel he is sitting on a soft surface (DD 20471). They can also becushioned at the same time with spring members, as in WO 93/03652 A orDE 198 28 254 C2. A low, space-saving overall height is not possible dueto the plurality of component members. However, if the construction ofthe spring member, as in FR 10 74 160 A or FR 12 68 632 A, is taken intothree dimensions, the individual loops of this plastics material springmember are not springy on an individual basis which means thatadditional cushioning has to be provided by means of a framework.

[0009] A use of a spring suspension mat on a vehicle seat is known in DE199 02 464 A1, where a plurality of flat supporting regions is providedwhich are connected, where required, to webs provided with springs. Theentire structure has to be tensioned in a framework. A similarconstruction is known in FR 27 59 649 A1 and DE 883 678 C. Springing isonly possible in a surface manner, which means that it is alsoimpossible to avoid tensile stress in the lower region. Consequently,the impression of sitting on something soft cannot be guaranteed as nospring means are provided transversely relative to the surface and nospring means are effective in a point-by-point manner. (Cf. also DE 1916 968 U, for which there are no longer any illustrations; EP 388 542A1).

[0010] A three-dimensional spring suspension mat is known in GB1,042,112, where the mat is produced in one piece from plasticsmaterial. This mat cannot be adapted to arbitrary contours due theholohedral connection. In addition, the spring members are notindividually deformable. In GB 2 055 173 A, contrary to this, in spiteof a three-dimensional construction, there is no flexibilitytransversely relative to the spring member, as this spring suspensionmat has wide, flat spring members. (Cf. also AT 405 481 B, DE 195 05 028A1 and DE 92 00 114 U).

[0011] In the field of beds, the disposition of spring members situatedperpendicularly relative to the lying surface is known in mattresses andbed bases (GB 614,272 and FR 15 80 446 A). Likewise DE 20 46 445 A alsomakes known disposing individual spring poles adjacent each other butonly interconnecting them at the edge of the base. This leads toadditional degrees of freedom and to bending under load, which meansthat the desired effect of a soft flat impression disappears. Solutionswhich are high in construction with at least resilient spring memberswhich are not point by point are known in this field, for example, DE 7929 543 U, DE 846 158 C, EP 972 470 A1, FR 955 776 A, WO 96/39906 A, DE132 171 C, DE 132 558 C, DE 19 75 358 U, DE 20 15 659 C, DE 344 247 C,DE 357 703 C, DE 475 144 C, GB 614 133 C, GB 917 563 C, GB 934 658 C, WO00/11989 A.

SUMMARY OF THE INVENTION

[0012] Proceeding from this state of the art, it is the object of thepresent invention to create the desired impression, in an alternativemanner, of sitting on something soft and saving space in so doing.

[0013] This object is achieved through the spring suspension mat withthe features of claim 1.

[0014] The spring suspension mat comprises resilient spring members,which are disposed in an arbitrary disposition adjacent each other inone direction and are interconnected transversely relative to thisdirection. This is how the impression of sitting on something soft iscreated without any further auxiliary means. The achievement is, namely,as with upholstery, a member, which is resilient in the surface,providing suitable spring comfort. The individual spring parts yield ina point-resilient manner, where necessary, as far as the reduction totheir material strength. The overall height of the spring suspension matpreferably even corresponds almost to the spring excursion. However, ifa three-dimensional spring resilient member is desired, the mat can alsoextend in the third dimension. Nonetheless, the members can be usedindependently of other parts of the seat, which is of advantage, moreespecially, when the vehicle is recycled at the end of its life.

[0015] Metal spring-steel cross bands are preferably disposed adjacenteach other and are interconnected transversely relative thereto by meansof cross-struts or flat connecting means. This is how to create aconstruction, which is more flexible in the surface itself, isconsequently also three-dimensionally deformable, and is formable intoalmost arbitrary three-dimensional contours. Through the transverseconnections, the spring suspension mat is a unit, which can be used inconstruction and can nevertheless be adapted to any arbitrary fixed basesupport. A separate holding or tensioning frame is no longer necessary.

[0016] In a preferred specific embodiment, the spring suspension mat isused on a fixed base support. This fixed base support, such as, forexample, a seat shell or the like, acts as the substructure for thespring suspension mat, which in contrast can still nevertheless bespringy in the smallest space on account of its point resilience likethe upholstering known up to now.

[0017] Further advantages are produced from the sub claims.

BRIEF DESCRIPTION OF THE FIGURES

[0018] The invention is described in more detail below by way of theenclosed Figures. In which:

[0019]FIGS. 1, 2 show a spring suspension mat shown in top view and insection,

[0020]FIG. 3 is a spring suspension mat as a composite material shown insection,

[0021]FIG. 4 is a sectional view of a spring member,

[0022]FIGS. 5-7 show another specific embodiment of a spring suspensionmat preferably made of metal shown in section, top view and in athree-dimensional view,

[0023]FIGS. 8-10 show another specific embodiment of a spring suspensionmat preferably made of plastics material and shown in section, top viewand in a three-dimensional view.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0024] The invention will now be explained in more detail by way ofexample with reference to the attached drawings. However, the practicalexamples are only examples, which should not restrict the inventiveconcept to a specific arrangement.

[0025]FIG. 1 is a top view of a spring suspension mat 10, as is moreespecially used for the cushioning of seats, preferably automobilevehicle seats. The use of the spring suspension mat is not restricted,however, to seating surfaces and back rests of all kinds of chairs suchas office chairs, seats, sofas or automobile and airplane seats, but canfor example also be used for beds or bicycle saddles. In principle, thecushioning mat is suitable for all types of use where resilientcushioning of surfaces, free of pressure points, is required.

[0026] In the case of this cushioning mat, spring members 11 aredisposed adjacent each other and are interconnected for operativeconnection transversely relative to their longitudinal extension, thatis relative to the first direction. The first direction extends parallelto a surface of the chair, bed or the like, which is usable by a user.The spring members have spring parts 12 a, 15 a, which are slightlyraised transversely relative to the usable surface. The spring parts 12a, 15 a are, however, portions of the spring members 12, which areintegral with the spring members, and are generally and continuouslyformed from the latter. Nevertheless the spring parts 12 a, 15 a areresiliently—so-called point resiliently—deformable, where required,individually, independent of each other and they are also deformable,where required, relative to the rest of the spring member. Thisdeformability is facilitated by the spring parts not being pre-tensionedin the initial condition of the spring suspension mat 10. The springmembers are interconnected for operative connection transverselyrelative to their first direction via connecting means 13, 14, 16substantially parallel relative to the surface. Spring members 12, 15and connecting means 13, 14, 16 can themselves be configured in a spacesaving manner consequently with no additional auxiliary means, which, onthe one hand, makes three-dimensional constructability possible, but, onthe other hand, makes a separate installation frame or tensioning framesuperfluous. The spring suspension mat is preferably used on a fixedbase such as, for example, a shell which corresponds to the desiredshape, the disposition of the spring parts, nevertheless, giving theuser the impression of conventional upholstery.

[0027] The spring members 12, 15 are preferably metal and consequentlynot difficult to recycle at a later date. More especially in the case ofa metal embodiment, the mat on account of the top material—is in allcases flame-resistant and not combustible, which is particularlysignificant in the construction of automobile vehicles and airplanes.Other materials, however, can also be used as long as the desiredresilient characteristics are achieved. In principle, the spring memberscan be disposed adjacent each other in an arbitrary manner as long as itis simply guaranteed that a suitable force transference to achieve thedesired spring comfort, that is to say the impression of sitting onsomething soft on the seat, is guaranteed. The spring members 12, 15 arepreferably disposed substantially parallel to each other, as can be seenin FIG. 2. In the exemplified embodiment, the spring parts protrudeupwards from the spring members 12, 15; a reversed installation wherethe spring parts 12 a, 15 a, protrude downwards from the spring parts isalso equally possible.

[0028] A spring suspension mat of this type will be a flat constructionfor the most part, which is also deformable, however, in the thirddimension, where necessary, on account of the transverse connection bymeans of the connecting means, that is to say, for example, it isadaptable to the contour of a seat. If, however, a three-dimensionalspring resilient member is desired, the mat can also extend in the thirddimension. In this case, a connection between various spring members canalso be effected in the third dimension. Through the transverseconnections, the spring suspension mat is a constructible unit, whichnevertheless adapts to any arbitrary fixed base.

[0029] The Figures show spring members 12 made from spring-steel crossbands with a width u. To achieve a better spring effect, thespring-steel cross band is bent upward to a height v in a loop-shapedmanner. The height v of the spring suspension mat can be reduced down to10 mm below or less mounting height without loss of the sitting-down orlying-down feeling striven for, which results in a construction which isextremely space and also weight saving, as the spring suspension mat isalso the seating surface. Nevertheless there is good springinessprecisely on account of the capability of the spring parts to fold-up.The overall height of the spring suspension mat corresponds namelyalmost to the spring excursion of the spring parts. The individualspring parts give way in a point resilient manner, where necessary, upto the reduction to their material strength without any plasticdeforming occurring. Arbitrary overall heights are possible, howeveroverall heights between 8 and 20 mm, preferably 10 mm are possible. Thisconstruction type consequently also results in an additional support,more especially where it is used in an automobile vehicle, as lateralmovements are possible only over the overall height, which is anadvantage compared to conventional upholstery.

[0030] To achieve an operative connection, these spring members 12 canbe interconnected by means of a flat connecting means 13 (FIG. 3). Theconnecting means can be glued to the spring members. It can be disposedon one side or on both sides of the spring suspension mat 10 with thespring members 12. In principle, for example, a central connecting meanscan also be in operative connection with spring members on both sides.The connecting means 13 can, for example, be in the form of a mesh, alayer, a mat or a film. In these cases too, a three-dimensionalstructure can be achieved by means of disposing spring members andconnecting means in a corresponding manner.

[0031] As an alternative thereto or in addition thereto, the springmembers are interconnected preferably by means of resilient transversestruts 14. This connecting through transverse struts 14 is moreespecially suitable where spring-steel cross bands are used as thespring member 12. Compared to previously known spring suspension mats,this connection facilitates a three-dimensional formability of thespring suspension mat 10. In principle, it is possible to develop thespring conditions as being variously hard or soft by using differentmaterial strengths over the seating surface. In other words, variousspring-steel cross bands can be used adjacent each other. This meansthat a specific springiness can also be achieved in a targeted mannerinternally of or within the surface.

[0032] The spring-steel cross band in FIG. 1 has a different bendingradius to the spring-steel cross band in FIG. 4. This can also influencethe resilience of the spring suspension mat. However, the smaller thebending radius, the better the respective loop, bend, diamond or thelike made of spring-steel cross bands can spring inwards. If a smallbending radius is selected, as, for example, in FIG. 4, the bent memberscan be compressed with a resilient deforming as far as almost zero, moreconcisely put as far as approximately the material strength of thespring parts 1 2 a in the direction of load transversely relative to theusable surface—in the exemplified embodiment three times the materialstrength of the spring parts 12 a. However, as this occurs for each bendindependently and in a varyingly strong manner depending on the load,this leads to the impression of sitting on something soft and free ofpressure. Each spring part 12 a, 15 a has at least four, in theexemplified embodiment in FIGS. 4 to 10 five bending points, from whichat least four are configured with a small bending radius in order toachieve the “folding-up” of the spring parts. Consequently, theindividual spring part can be folded-up in places, which means that,when bending, on the small bending radii the material can be folded-upas far as its material strength. This leads to a large spring excursionwith a small mounting height. The bending radii are designed in such amanner in this case that, nevertheless, there is no plastic deformation.This design imitates the design of a leaf spring, the external cornerpoints 12 b, 15 b being pressed approximately regularly outwards underpressure with the lowering of also the upper central point 12 c, 15 c.The compressive and tensile stresses generated at the same time in theupper and lower portions of the spring parts are eliminatedsubstantially, which means that—if at all—small transverse forces aretransferred into the members situated in the base surface themselveswhen used on a fixed base.

[0033] In the exemplified embodiments in FIGS. 1 to 7, the springsuspension mat has several strips with arbitrary widths and lengths asspring members 12. In place of the spring-steel cross bands, plasticsmaterials or other resilient materials can be used, albeit preference isgiven to the metal spring member. The individual strips can be connectedto the connecting means 13, 14 in the most varied of manners. A hollowrivet or a laser weld, for example, can be used for the connectionbetween the spring members 12 and the connecting members 14. However,the spring members 12 can also be assembled, for example, as a plasticsmaterial injection molded part. A corresponding specific embodiment isrepresented in FIGS. 8 to 10. The spring members 15 rise out of a basesurface 16. A corresponding part can be injection molded or can also bedeep drawn from a plastics material part—or also a metal part—by way ofplastic deformation.

[0034] In both cases, a holohedral sitting feeling with no noticeablepressure points, unlike previously known spring members or springsuspension mattresses, can be achieved by means of the tightly adjacent,high number of contact points in the direction of the surface “to be satupon”. Following assembly from individual members, the mat is suitableunder load for any body shape, comparable to a water bed.

[0035] The spring suspension mat 10, for example comprising the springmembers 12 and the connecting means 13, 14, can be constructed as acomposite material which is used in seats, more especially in vehicleseats. This composite material can in its turn include parts of thevehicle seat such as the upholstery. The composite material can also bean integral component part of the vehicle seat or of parts of thevehicle seat.

[0036] The spring suspension mat is produced in all sizes and shapes,such as, for example, rectangular, square, oval, round, triangular andso on. The mat can be produced with defined sinking depths and hardnessat arbitrary points, as for this purpose only a corresponding selectionof spring members or their shape for these points or respectively atthese points is necessary. The mat is very flexible and is suitable forall possible basic shapes depending on the area of application. To thisend, the mat does not have to be additionally plastically deformed, forexample through angling, bending or the same. The mat follows anarbitrary basic outline. Additional supports and/or shaped frameworkscan be used, but they are not absolutely necessary as the springsuspension mat, where necessary, can be reinforced in itself andnevertheless still offers the desired spring comfort through the springparts 12 a, 15 a. The spring suspension mat is preferably used on anarbitrary fixed base, such as, for example, a shell, perforated wherenecessary. On account of its design, it can be adapted to the contour,but due to the point resilience allows a springiness as with previouslyknown upholsteries. For the same reason, the spring suspension mat doesnot lose its outer shape under compressive load as the pressure isabsorbed by the fashioning of the individual spring members.

[0037] It is obvious that this description can be subject to the mostvarying modifications, changes and adaptations, which vary in the regionof equivalents to the attached claims.

1. Spring suspension mat for the cushioning of all types of seats, bedsor chairs, said spring suspension mat comprising: spring members, whichare disposed in a first direction adjacent each other substantiallyparallel to a surface which is useable by a user, with a plurality ofspring parts which are raised transversely relative to the useablesurface and form with the spring members one-piece portions of thespring members and are formed from these latter, wherein the springparts are deformable individually, independently of each other in aresilient manner also relative to the rest of the spring member, areinterconnected via connecting means transversely relative to their firstdirection substantially parallel to the surface for operativeconnection, wherein the spring parts have at least in places such asmall bending radius that the spring parts, when there is a resilientdeformation, where necessary, are reducible up to approximately thematerial strength of the spring parts, then being in the folded-togethercondition, in a loading direction transversely relative to the useablesurface.
 2. Spring suspension mat according to claim 1, wherein themounting height of the spring suspension mat corresponds approximatelyto the spring travel of the spring parts.
 3. Spring suspension mataccording to claim 1, wherein the spring members are interconnected bytransverse struts in the form of connecting means.
 4. Spring suspensionmat according to claim 3, wherein said transverse struts are resilient.5. Spring suspension mat according to claim 1, wherein the springsuspension mat with spring members and connecting means forms a surfacecomprising a three-dimensional form.
 6. Spring suspension mat accordingto claim 1, wherein the mat is disposed on a fixed support correspondingalmost to the desired outline of the seat or of the like.
 7. Springsuspension mat according to claim 1, wherein the spring parts are in theform of a diamond resting on one point, said diamonds being continuouslyformed from the spring member through at least four.
 8. Springsuspension mat according to claim 1, wherein the spring members, whichare disposed substantially parallel to each other, are metal.
 9. Springsuspension mat according to claim 8, wherein the spring members are madefrom spring-steel cross bands or at least include spring-steel crossbands.
 10. Spring suspension mat according to claim 1, wherein thespring members are interconnected for operative connection by means of aflat connecting means, which is disposed on at least one side of thespring suspension mat and is glued to the spring members or is connectedthereto in another manner and is formed by a mesh, a layer, a mat or afilm.
 11. Spring suspension mat according to claim 1, wherein the springsuspension mat is produced from plastics material by means of injectionmolding or deep-drawing.
 12. Spring suspension mat according to claim 1,wherein the spring suspension mat, at least comprising the springmembers and the connecting means, forms a composite material for use inseats or vehicle seats.
 13. Spring suspension mat according to claim 12,wherein the composite material includes further parts of the vehicleseat and/or is an integral component part of the vehicle seat or partsthereof.
 14. Spring suspension mat according to claim 1, wherein thespring members and spring parts are situated so closely adjacent eachother that a flat impression is produced through the number of supportpoints.
 15. Spring suspension mat according to claim 1, wherein theoverall height of the spring suspension mat is between 8 and 20 mm. 16.Vehicle seat with a spring suspension mat according to claim 1.